Circumferential and longitudinal cutter coverage in continuation of a first bit diameter to a second expandable reamer diameter.

ABSTRACT

The Smart Reamer® Tool, Apparatus or Method is used to underream an oil or natural gas well while interlinked calipers and calibration sensors simultaneously record data relating to the geometry of the drilling operation (well diameter, diameter of the underreamed zone) and drilling fluid properties (density). Further sensors provide data on the relative position of the cutting and stabilizing blocks. Other sensors measure vibration data. All the sensors are interlinked by means of microprocessors which compare and correlate said data to automatically verify and deliver a desired wellbore diameter without the need to unnecessarily stop drilling or trip out of the hole.

This application entitled “CIRCUMFERENTIAL AND LONGITUDINAL CUTTERCOVERAGE IN CONTINUATION OF A FIRST BIT DIAMETER TO A SECOND EXPANDABLEREAMER DIAMETER” is a divisional of co-pending U.S. patent applicationSer. No. 13/949,286 filed Jul. 24, 2013, which is a continuation of U.S.Ser. No. 12/966,195 filed Dec. 13, 2010, and entitled “DRILLING TOOL,APPARATUS AND METHOD FOR UNDERREAMING AND SIMULTANEOUSLY MONITORING ANDCONTROLLING WELLBORE DIAMETER”, which is a continuation-and-part ofInternational Application number PCT/ES09/70261, filed Jun. 27, 2009 andentitled “DRILLING TOOL AND METHOD FOR WIDENING AND SIMULTANEOUSLYMONITORING THE DIAMETER OF WELLS AND THE PROPERTIES OF THE FLUID”, andclaims priority to and the benefit of GB 0811815.0, filed Jun. 27, 2008and entitled “EXPANSION AND CALLIPER TOOL”, the entireties of whichapplications are hereby incorporated by reference as if fully set forthherein.

FIELD OF THE INVENTION

This invention relates to an integrated expansion and caliper toolcapable of simultaneously enlarging and measuring borehole and tubulardiameters, especially, underreamed wellbores in the oil and gasindustry. The expandable blocks of the tool can be configured withcutting or stabilising elements while the calipers can be acousticsensors or mechanical gauge probes to measure the underreamed wellborediameter. Further measurements can be obtained from a calibration sensorthat measures fluid properties. Other measurements can be made by blockpositional sensors and vibration sensors independent of the former.

It is to be understood that the term ‘expansion’ as used herein refersto the capacity of the tool to expand outwardly and against the interiorwall of a passage, such as a borehole, especially a wellbore, or atubular used as a casing, and then to apply pressure or a cutting actionagainst the wall. It is not always essential that the wall itself beexpanded, since the tool can be used for centralisation or stabilisationor like purposes without necessarily expanding the passage.

When constructing an exploration or production well, numerous downholeoperations are conducted to drill and measure the borehole so that itmeets the desired dimensions specified in the well-plan. Drillingoperations may utilize a reamer to ensure that the hole diameter thathas been drilled by the bit is maintained within the given tolerance forthe plan. The hole diameters drilled by the bit and perfected by thereamer are substantially the same. The maximum cutting diameter of thereamer, which is fixed, is substantially the same as the bit diameter.This maximum cutting diameter is defined by the pass-through diameter ofany restriction in the borehole above the operating location.

In contrast to a reamer, an underreamer is used to enlarge the diameterof the borehole beyond its original drilled size. Enlargement(underreaming) is typically done below a restriction in the borehole,and the cutting diameter of an underreamer is always greater than thatof the pass-through diameter of the restriction. Additionally, anunderreamer is provided with activation and deactivation modes andmechanisms for extending and retracting cutting elements to ensureeffective underreaming once it has passed below the restriction.

Measurement may involve the acquisition and communication to surface ofvarious types of wellbore data such as resistivity, porosity,permeability, azimuth, inclination and borehole diameter or rugosity,formation dips or bedding angles.

Measurement itself occurs in two modes, either wireline orlogging-while-drilling. Wireline is the most common measurementtechnique and is performed as a separate and consecutive activity todrilling, involving the conveyance of measurement tools on a wire orcable. Wireline calipers use a plurality of fingers to take boreholediameter measurements. However, wireline calipers can only takemeasurements in an axial direction. Due to this limitation, they canonly be used after drilling otherwise the rotational and impact forcesof drilling would cause them to break. Hence a separate caliper run isrequired after drilling to measure borehole diameter.

Logging-while-drilling tools may acquire various data from the wellbore.Acoustic calipers may be incorporated within logging tools such asneutron density tools. As they can be rotated, acoustic calipers may beused while drilling to acquire measurement data. However, almost alllogging tools are configured as complete systems and are only availableat very high cost and used in a low percentage of wells worldwide.Further they also suffer from limitations in applications with slidedrilling, where a downhole motor rotates the bit and drags thedrillstring and bottom-hole assembly (BHA). In rotary steerableapplications the logging tools are configured near to the bit.Therefore, the location of the acoustic caliper is within the BHA belowthe underreamer at a considerable distance away from the underreamer.

Furthermore, prior art acoustic calipers are susceptible to erroneoustime of flight readings due to changes in the density of drilling orwellbore fluids. The configuration and lack of calibrated in-situdensity or sound time of flight fluid measurements present difficultiesfor prior art acoustic calipers.

Borehole measurements do not always rely on acoustic calipers. Actually,it is routine for borehole measurements to be taken in a separateactivity after drilling or underreaming (wellbore enlargement) has takenplace.

The time-lag associated with the separated operations of underreamingand measurement leads to uncertainty and unnecessary cost. In the caseof underreaming, measurements are taken a posteriori, which means aseparate caliper run and at times further corrective underreaming runsto attain the desired wellbore diameter.

BACKGROUND OF THE INVENTION

Oil and gas accumulations are found at depth in different geologicalbasins worldwide. Exploration and production of such accumulations relyon the construction of a well according to a well plan.

Various well types exist and are defined according to usage such aswildcats or those used in exploration, delineation, and production andinjection. Variations in well profile exist also according to vertical,slant, directional and horizontal trajectories. Each well differsaccording to the oil company's objectives and the challenges that agiven basin presents from the surface of the earth or the ocean toreaching the hydrocarbon reservoir at a given underground depth.

Engineering challenges are related to the location of the well-site suchas onshore or offshore, seawater depths, formation pressures andtemperature gradients, formation stresses and movements and reservoirtypes such as carbonate or sandstone. To overcome these challenges, ahighly detailed well plan is developed which contains the wellobjective, coordinates, legal, geological, technical and wellengineering data and calculations.

The data is used to plot the well profile, and plan its execution usingprecise bearings, which is designed in consecutive telescopicsections—surface, intermediate and reservoir. To deliver the wellobjective and maintain the integrity and operating capacity of the wellover its lifecycle, a given wellbore with multiple sections anddiameters is drilled from surface. Although there are many variants, asimple vertical well design could include the following dimensions: asurface or top-hole diameter of 17½″ (445 mm), intermediate sections of13⅝″ (360 mm) and 9⅝″ (245 mm) narrowing down to a bottom-hole diameterof 8½″ (216 mm) in the reservoir section.

Each consecutive section is ‘cased’ with a number of metal tubes placedinto the wellbore with the specified diameter according to the length ofthe section. Casing tubes are connected to each other after which theyare cemented into the outer wall of the well. In this way, a well isconstructed in staged sections, each section dependent on the completionof the previous section until the well is isolated from the formation inquestion along the entire distance from surface to the reservoir.

Scarcity of oil and gas is driving oil and gas companies to explore anddevelop reserves in more challenging basins such as those inwater-depths exceeding 6,000 ft (1800 m) or below massive salt sections.These wells have highly complex directional trajectories with casingdesigns including 6 or more well sections. Known in the art as‘designer’ or ‘close tolerance casing’ wells, these wells have narrowcasing diameters with tight tolerances and have created a need toenlarge the wellbore to avoid very narrow reservoir sections and lowproduction rates.

Therefore, the bottom-hole assemblies that are needed to drill thesewells routinely include devices to underream the well-bore below a givencasing diameter or other restriction. In this way, underreaming hasbecome an integral part of well construction and there is now anincreased dependence on underreaming to meet planned wellbore diameters.After underreaming, the underreamer is tripped out of the borehole andreplaced by the caliper, which is an instrument for measuring theinternal dimensions of the wellbore either mechanically, using extendedfingers that contact the wall of the wellbore, or by acoustic techniquesusing reflected acoustic signals from the wall of the wellbore.

Previously, the underreamer and caliper have been considered as twoseparate tools, each involved in distinct functions. Typically, anunderreaming run could take 24 hours, after which a further 24 hourswould be required for preparation of the caliper run. A further 24 hourscould be taken in the caliper run before knowledge could be gained ofactual wellbore diameters. This time-lag between underreaming andcaliper measurements therefore could easily exceed 48 hours depending onthe depths involved. If the actual hole diameter did not match theplanned diameter, casing tolerances would not be met and a correctiverun would be required. Consequently, the whole cycle of underreaming andcaliper measurements would need to be repeated.

In other applications such as expandable tubular or increased cementingthicknesses, the tolerances between the enlarged well-bore and theexpanded steel tube and cementing thickness are very close. Variationsof 1″ (25 mm) in the diameter can lead to the failure of the wellconstruction activity.

SUMMARY OF THE INVENTION

The present invention has for a principal object to provide animprovement on the prior art in wellbore underreaming and wellboremeasurement wherein the actual diameter of the underreamed hole ismeasured directly in real time, that is to say simultaneously with, orimmediately after, a wellbore expansion operation.

The invention is based on an integrated underreamer and caliper tool orapparatus that is equipped with one or more means for measuring theunderreamed wellbore diameter and calibrating said wellbore diametermeasurements using drilling fluid properties sensors to provide realtime performance verification, automated troubleshooting and delivery ofdesired wellbore diameters.

The present invention seeks to integrate and automate underreaming andcaliper measurements and eliminates the need for separate caliper runsand minimizes the need for corrective underreaming runs by providingreal-time data which allows the driller to respond earlier therebysaving time and money on wellbore operations.

It is thus an object of the present invention to provide underreamingexpansion blocks integrated with calipers for measuring the underreamedwellbore diameter, enabling the tool to give immediate measurements ofthe accuracy of the wellbore-widening operation and, if the diameter isfound insufficient or undergauge, to automatically detect and diagnosethe potential faults, and to repeat underreaming until a satisfactoryresult is achieved.

Although underreaming is the principal route to wellbore diameterenlargement, the invention may be applied to alternative enlargementmeans integrated with measurement calipers that use bicentre bits, fixedwing bits, eccentric underreamers and expandable bits.

In one embodiment, the tool is capable of simultaneously conductingwell-bore enlargement, taking caliper measurements using an acousticecho-pulser and sensor, and verifying performance through amicro-processor that uses caliper measurements which are calibrated bymeans of drilling fluid properties sensors. This enables the tool todetect undergauge hole and conduct diagnostics according to a logiccircuit. In this way, the user can achieve a planned or desired wellborediameter and at any given time check that the underreamer is functioningcorrectly. Whenever a problem occurs and if the corrective steps havebeen taken and the caliper indicates that the desired hole diameter isstill not being delivered a signal may be sent to the rig-surface or tothe location of the operating engineer so that further remedial actioncan be taken, according to a logic circuit. This may include extendingcutter blocks in response to caliper data, checking block positions orany number of logic steps. A memory card may store sensor informationthat can be downloaded at surface when the tool is retrieved, or sent tothe surface by telemetry.

The tool may also have a built-in link to a mud-pulse telemetry systemto allow real-time monitoring of the under-reaming operation (calipermeasurements, fluid properties calibration data and simultaneouslycutter-block position). One or more mechanical calipers (gauge probes)or acoustic echo-pulsers may be optimally spaced in order to emit anumber of sound waves during a given time period which are reflectedback by the near wellbore or by the far formation in the case of acavernous formation and picked up by a sensor installed in the sametool. The travel or transit time of the sound waves at a given speed canbe processed by the micro-processor and integrated with calibrationmeasurements in order to accurately determine the distance travelled andthe wellbore diameter measurement.

A keyway may provide a channel for wiring from the sensors to theprocessor and transponder. The wiring can be used to transmit acousticdata retrieved by the acoustic sensors, the fluid properties calibrationsensor as well as positional data from the mechanical blocks, to theprocessor. The processor can process this data and sends it to thetransponder to be sent to the control system at the surface. The keywaymay be sealed and filled with a means to absorb vibration such assilicone gel or grease and to maintain wires in position.

The transponder converts data sent by the processor so that it can betransmitted to the surface by means of the mud-pulser which uses aseries of binary codes at a given frequency using drilling fluid asmeans of transmission. Other means of wireless transmission can be used,using radio frequency or electro-magnetic pulses. This allows up anddownlink of the tool in order to receive and transmit data and commands.The data may be transmitted to the surface for use by the drillingoperator or may be further transmitted by satellite to a remoteoperations centre.

One embodiment of the invention provides for a wellbore underreamingtool or apparatus, which is particularly applicable in oil and naturalgas wells, arranged for attachment to a rotary drill-bit and associateddrill-pipe, which comprises at least one radially extendable cutterblock (62), at least one caliper (76 or 64-66) to determine the wellborediameter, a fluid properties calibration sensor all of which areintegrated within the body of the tool and inter-connected by means of amicro-processor to verify and control a desired wellbore diameter (22)through comparison and correlation of the simultaneous measurements fromthe caliper and the fluid properties calibration sensor.

The tool support may be the drill string but it may also be a length ofcoiled tubing.

The tool body is a cylindrical high grade steel housing adapted to formpart of the bottom-hole assembly by means of a screw connection arrangedat the end of the tool, which is coupled to the drill bit. Theattachment need not be direct, but may be indirect, depending on therequirements of the different elements of each drill string and eachwell. The lower end of the BHA may be a drill bit, or a bull nose, andthis part and the tool there may or may not be a means for directionalcontrol of the wellbore such as a rotary steerable system.

In one embodiment of the invention, the expansion operation is anunderreaming application, and expansion elements comprise a set ofcutter blocks optimally configured with cutter inserts and nozzles. Inanother embodiment, the expansion elements may comprise expansionblocks, which may be of similar construction to the cutter blocks, buthaving outer surfaces where cutter elements may be replaced by ahardened material. Such expansion blocks may simply bear under pressureagainst the inside of a tubular wall, with sufficient force to deform itoutwardly to a larger diameter. In yet another embodiment, the sameblocks may simply bear against the underreamed wellbore in order tostabilize the tool within the wellbore without enlarging the bore. Thesame blocks maybe received within an additional section of the tool or aseparate steel body suitably prepared to provide a means ofstabilization to the expansion operation. In a further embodiment, thesame blocks maybe received within an additional section of the tool or aseparate steel body suitably prepared as apparatus to provide a means ofstabilization for underreaming applications.

In one embodiment where the wellbore expansion activity is underreamingthe cutter blocks are situated within the tool body in an open chamber,the outer surface of which is composed of a plurality of high strengthcutter elements such as polydiamondcrystalline inserts arrangedexternally. The cutter block is provided with a flow of drilling fluidvia an external nozzle adjacent to the set of cutters which allowsdrilling fluid to flow from an internal bore connected to a source ofsaid drilling fluid.

In another embodiment, the tool comprises a module that can be coupledby means of a thread connection to the body of the tool which comprisesexpandable stabilizing blocks in order to stabilize the tool against thewellbore walls during underreaming and measurement and if so required,increase or expand the diameter of the metallic tube casing of the well.

It is to be noted that the description herein of the expansion blocks isapplicable generally, irrespective of the function of cutting, expansionor stabilization of the drill string. Thus, the cutter blocks areprovided with cutting inserts or teeth to enable underreaming of thewellbore that may be replaced by hardened smooth surfaces for expansionoperations of an expandable steel tubular inside the wellbore.

In one embodiment the microprocessor control means (68) are adapted toreceive, during drilling operations, information simultaneously from thecaliper for measuring the wellbore diameter and from fluid propertiessensors as well as the positional sensors of the extendable cutter blockin order to control the extension and retraction of said block inresponse to caliper data or according to the logic circuit in order todetect and correct failures in real-time and achieve the desiredwellbore diameter.

The tool normally comprises a plurality of such cutter blocks, arrangedsymmetrically around the tool. Two cutter blocks would be on oppositesides of the tool, three blocks would be separated by 120 degrees, fourblocks by ninety degrees, and six by sixty degrees. In operation, thetool is typically rotated together with the drill string as well asbeing moved axially along the wellbore.

The tool body is provided with an internal bore for receiving drillingfluid via a device nozzle adjacent the cutter. In each case, the nozzlesprovide a fluid flow that help to keep the cutters clean and prevent thebuild-up of clogging debris from the underreaming operation and providea cooling and lubricating function for the cutters. In one preferredaspect of the present invention the tool incorporates a non-mechanicalmeans of measurement such as an acoustic caliper for measuring theunderreamed wellbore diameter.

The calipers for measuring the underreamed wellbore diameter with whichthe underreamer is equipped emit sound pulses that are reflected fromthe wellbore walls. These reflected echoes are used to calculate thedistance by multiplying time by the propagation speed of the acousticpulse or the sound transit time. The underreamed wellbore diametercalipers are generally located in the tool body above the underreamerbut in an alternative configuration of the tool may be placed within thecutter block itself in the most radially extended zone among the cuttingelements.

In a further embodiment, the invention provides for a method ofoperating an expansion tool or apparatus to underream a borehole to adesired dimension below a restriction, which comprises locating saidtool or apparatus in said borehole on drill-pipe below a restriction,measuring the wellbore diameter by the caliper means, simultaneouslycalibrating said caliper measurements, extending a set of cutter blocksto an expansion diameter greater than the restriction, rotating the tooland moving it axially along the borehole on the drill string or othersupport, measuring wellbore diameter by said caliper means andcontinuing underreaming until the desired dimension is achieved.

In accordance with the method of the invention, the tool may be providedwith expandable cutter control means responsive to dimension datareceived from the caliper means. In this way, an integrated tool andapparatus which is capable of diagnosing under-performance andcorrecting it may be realized. The dimension data may prompt for testsand checks on the effective deployment of the expandable blocks, maytrigger a repeated cycle of expansion, or activate a further set ofcutters and may provide data to a surface monitor to signal anopportunity for operator intervention.

Thus, in the case of an underreaming tool with acoustic caliper means,acoustic reflections from an echo-pulser may be transmitted to a sensorand calculated as distance by multiplying time by speed. The processorcorrelates the borehole data from the fluid properties sensor allowingfor variations in fluid or formations. The processor uses this data tocorrelate whether the pre-programmed wellbore diameter is actually beingunderreamed and measured. Where the processor detects a fault ordifference between the two minimum measurements it automaticallytroubleshoots the fault using a logical procedure.

The skilled operator will readily appreciate that other procedures maybe implemented by the logic circuit or control program within the tool'sprocessors, which can be programmed to cover other scenarios.

BRIEF DESCRIPTION OF THE DRAWINGS

The various embodiments of the invention are illustrated by way ofnon-limiting examples in the accompanying drawings, in which:

FIG. 1 is a general diagrammatic view of an oil or gas well showingsurface structures and the interior of the underground wellbore, with atool in accordance with the invention as part of the final bottomholeassembly;

FIG. 2 is a longitudinal section of the tool and apparatus according toone embodiment showing the expansion elements constituted by both cutterblocks and stabilizer blocks in a deactivated state;

FIG. 3 is a cross section of the tool as seen from the drill bit,showing the diameters of the drill bit, of the pass-through casing andof the desired underreaming of the wellbore in accordance with theinvention shown in the previous Figures, in the operative mode of theexpanded expansion cutter blocks (activated operating mode);

FIG. 4 shows a cross-section of the tool as seen from the drill bit,showing the diameters of the drill bit, of the casing and of the desiredunderreaming of the wellbore, according to the invention shown inearlier figures in the operative mode of the retracted expansion cutterblocks (deactivated operating mode);

FIG. 5 shows a cross-section of the body of the tool showinglongitudinal open channels which allow drilling or wellbore fluid topass through and where the fluid properties transmitter or sensor deviceis placed. FIG. 5 b corresponds to FIG. 5 and shows an alternateembodiment of a longitudinal open channel especially suited to anintegrated transmitter/receiver (transducer).

FIG. 6 is a general view of the well illustrating telemetry of theunderreaming and drilling data recorded by the tool or apparatus;

FIG. 7 corresponds to FIG. 6 but illustrates downlink telemetry of thedata with parameters sent in order to control the underreaming anddrilling by the tool or apparatus; and

FIG. 8 is an algorithm and shown as an exemplary diagnosis andtroubleshooting procedure for operational aspects of the underreamingand measurement of the drilling variables according to the invention.

FIG. 9 is an enlargement of part of FIG. 2 showing an expansion blockconfigured with cutters;

FIG. 10 is a view corresponding to FIG. 9 showing an alternativeconstruction with external nozzle;

FIG. 11 is a longitudinal section of one embodiment of the tool orapparatus showing the expansion elements constituted by a set of cutterblocks and a further set of cutter blocks in a deactivated state;

DETAILED DESCRIPTION OF THE INVENTION

As shown in FIG. 1, an exploration or production rig comprises a surfacestructure (10) at the wellhead, a wellbore (20), a drill string (30) inthe wellbore and a bottom-hole assembly (40) at its lower end where thetool or apparatus (50) may be configured according to the presentinvention with the desired configuration of modules: module housing theexpandable cutter blocks, module housing the calipers, sensors andprocessors and the module with expandable stabilizer blocks orexpandable blocks to expand a tubular within the wellbore. The tool orapparatus (50) comprises at least one underreamer module integrated witha wellbore diameter measurement caliper tool incorporating a sensor tomeasure fluid properties and calibrate said caliper measurements, andcapable of connection to a drill-bit.

The longitudinal section of the tool illustrated in FIG. 2 comprises asteel tool body (52) provided with an internal flowbore (90) and amud-pulser (56), which is adapted to be engaged by a further drillcollar (not shown) to connect it to the other elements of thebottom-hole assembly (40), and then to the drill string (30) as requiredby the drilling operation.

The tool body is also provided with elements for cutters (60) andstabilizers (61), a wellbore diameter measurement caliper (76 or 64-66)uphole of the cutter blocks (62). The expandable cutter (60) is composedof various cutter blocks (62) placed symmetrically and radially outwardsof the tool body (52) as shown in FIG. 2 in the de-activated status withthe blocks retracted inside the tool.

In one embodiment the tool incorporates an acoustic caliper comprisingan acoustic transmitter and receiver which can be housed within the bodyof the tool in sealed recesses (64 and 66 or 76). Tool performance isverified using the micro-processor (68) that compares data recorded bythe acoustic receiver (66 or 76) with the programmed wellbore diameter,thus detecting possible undergauge hole diameters. The tool is automatedaccording to logic control sequences stored in each processor (68) todeliver a desired wellbore diameter and in order to ensure theunderreamer is functioning correctly. Once verification and correctivesteps have been taken, and if the caliper for measuring the underreamedwellbore diameter (66 or 76) indicates that the required hole diameteris still not being delivered, a signal is sent via the mud-pulser (56)to the rig-surface (10) to allow control commands to be sent by theoperator either locally or by remote control. These control commandsadopt the relevant operative and corrective measures such asmodification of the pump flow rate of mud or drilling fluid, activationof cutter blocks in response to caliper data, replacement of thebottom-hole assembly etc. The memory card associated with the processor(68) stores data from the calipers, fluid properties measurementsensors. The said data is transmitted in real time in order to be usedin the underreaming and drilling operations (56) or physicallydownloaded by removing said card when the tool is retrieved from thewell.

The tool is provided with a built-in link to the telemetry system (56)which also serves to monitor performance of the under-reaming operation,position of expansion blocks (62) and data recorded by the caliper formeasuring the underreamed wellbore diameter (66 or 76) as well as datafrom the fluid properties sensor. One or more acoustic sensors (64 or76) are placed within the tool body (52) in order to emit a number ofsound waves during a given time period which are reflected back by thewellbore wall (FIG. 3, 22) and picked up by the receiver sensors (66 or76). The processor (68) calculates the distance using transit time andcalibrates transit time with data from the fluid properties sensors toestablish the speed of return of the acoustic waves and wellborediameter. The processor compares the measured wellbore diameter to theprogrammed desired diameter. If the two measurements match givenuser-defined tolerances the tool continues to operate to the total depthof the wellbore section to be underreamed. Where the measurements do notmatch the processor automatically activates a series of logic steps totroubleshoot the fault.

As further shown in FIG. 2, a keyway (74) provides a channel for wiringof the acoustic pulsers or transmitters (64 or 76) and the acousticsensor/receivers (66 or 76) to the processor (68), and also to thetransponder (72). In one embodiment the wiring is used to transmitacoustic data retrieved by wellbore calipers and fluid propertiessensors as well as positional data from the cutter and stabilizer blocksto the processors and transponders. The keyway may be sealed and filledwith a means to absorb vibration such as silicone gel.

The transponder (72) converts data from the processor (68) so that itcan be transmitted to surface (10) via the mud-pulser (56) whichtransmits the data to surface using a series of binary codes at a givenfrequency using the drilling mud itself as means of transmission. Othermeans of wireless data transfer may be used such as systems using radiofrequency or electro-magnetic pulses.

FIG. 2 also shows an alternative location for the caliper for measuringthe underreamed diameter which may be a caliper (76) arranged in anencapsulated recess connected to wiring in keyway (74) connected to theprocessor which may also be connected to the acoustic(transmitter/receiver) calipers (66-64) and a new keyway connection (78)which may be connected to an alternate processor (68) which controls anactivation motor (80) for the expandable block (62 or 63). FIG. 2 alsoshows an internal flow bore or axial through passage (90) in the tool toallow mud to flow through the whole bottom-hole assembly (40). Theencapsulated recesses (64, 66 and 76) may also be used to house othertypes of sensors such as a vibration sensor to detect stick-slipconditions.

The tool or apparatus may be configured in three modules integrated bymeans of screw connections (65) and (82). The body of all parts of thetool or apparatus (52) is a cylindrical high grade steel housing adaptedto form part of the bottom-hole assembly (BHA) (40) via internal screwconnections to ensure the through flow of drilling fluid (90). Theconnection may be direct or indirect depending on the needs of thedifferent drilling components of each BHA and each well. At the leadingdownhole end of the BHA there may be a drill-bit or a stabilizer andbetween this point and the tool there may be a wellbore directionalcontrol system. The stabilizing blocks (63) are constructed identicallyto the cutter blocks (62), except that in place of cutter elements (60)there is a surface which is hard faced (61) or coated with a hardabrasion-resistant material.

The hard faced surfaces of the stabilizer expansion blocks act tostabilize the drill string and eliminate some of the problems associatedwith the loss of directional control above the underreamer when thediameter in said zone is equal to that of the underreamer or greaterthan the pilot hole. Likewise, the tool can be used to expand or enlargethe diameter of metal tubes by deformation of the latter in thewellbore. In this case, the tool body facilitates the operation ofexpanding or enlarging the diameter of the expandable casing and isconnected to the downhole assembly by means of a screw connection insaid body.

The stabilizer module may be directly or indirectly connected to theunderreamer and hard-wired accordingly (74 a) to send data from theprocessor (68) to the transponder (72) through the mud-pulser (56) tosurface.

FIG. 3 shows an uphole front view of the bit illustrating the generallydesignated expandable cutters (60) in the activated mode, i.e. withcutter blocks (62) expanded outwardly of the tool body and supportedagainst the underreamed wellbore wall (22) which arises from thewellbore (20) which has not been underreamed. FIG. 3 shows thearrangement of the drill bit teeth in which there are ten curved rows ofcutters (44), with cutter teeth in each one. A central drilling fluidoutlet (46) indicates where drilling fluid passes through the internalflowbore (90) in the tool body (52). The direction of rotation of thebottom-hole assembly and of the drill bit is shown (124).

FIG. 4 illustrates the same front view as FIG. 3 with the expandablecutters (60) in a deactivated condition, i.e. with cutter blocks (62)retracted within the inner chambers of the tool body without exceedingthe wellbore diameter that has not been underreamed (20).

In one embodiment the caliper data itself from the underreamed wellborediameter caliper is calibrated using measurements from the fluidproperties sensors. The transit times of the fluid properties sensor isused to detect whether there is any change in wellbore or drilling fluidproperties which would require caliper measurements to be calibrated.When the processor detects a difference between calibrated measurements,the processor automatically corrects the transit time of the caliper toensure an accurate measurement.

FIG. 5 shows longitudinal open channels (150) known as “junk flow areas”where drilling fluid passes freely and incorporating fluid propertiessensors. At least one transmitter (210) and a sensor/receiver (160) arelocated at two fixed points facing each other, preferably embeddedwithin these channels and connected to a microprocessor in order topermit the measurement of fluid properties. In this way, for example,changes in sound transit time or the density of the fluid can bemeasured as the fluid passes through these channels during drillingoperations or as it remains in the channels during non-drillingoperations. The processor detects changes in the transit time or densityof the drilling or wellbore fluid and calibrates the acoustic callipermeasurements accordingly. FIG. 5 b corresponds to FIG. 5 and shows analternate embodiment of a longitudinal open channel especially suited toan integrated transmitter and receiver (transducer).

In a further embodiment of the invention, caliper measurements are notonly calibrated by means of fluid properties sensors but are comparedwith extended block positions. In this embodiment each expandable blockis provided with lines or magnetic strips that allow a sensor to detectthe actual position of the blocks. The magnetic signal is at itsstrongest when the block is fully extended and the magnetic line andsensor are aligned. In this way, it can be seen whether the block hasactually been extended and determine its extension length and position.This block positional data is sent to the processor where it is stored,compared and correlated with the caliper data to deliver a desiredwellbore diameter and also troubleshoot causes of failures. It is notnecessary for the block positional sensor to be on the block itself andin an alternate embodiment the sensor may be on the housing itself asthe purpose is to establish the relative position of the block to thetool.

As noted above, the invention provides a method of real-time drillingoperation and control, which uses an extendable tool to underream theborehole to the desired dimension passing through a restriction,activating the tool, extending the extendable cutter block to a diametergreater than that of the restriction, rotating the tool and moving itaxially along the borehole, enabling the simultaneous measurement andcalibration of the borehole diameter by the caliper for measuring theunderreamed wellbore diameter. Microprocessors connected to a controlarea act in response to data received from the caliper for measuring theunderreamed wellbore diameter, the calibration fluid properties sensorwith the objective of achieving the desired wellbore diameter andeliminate causes of errors or failures and minimizing drilling time bynot tripping in with another caliper or performing further underreamingcorrective runs.

FIGS. 6 and 7 illustrate how the underreaming tool may utilize means forcommunicating data from the caliper for measuring the underreamedwellbore diameter, the calibration fluid properties sensors, the blockpositional sensors or the vibration sensors and control signals betweenthe tool and a surface interface which may, among other functions,control the advance and trajectory of drilling during the underreamingoperation.

As shown in FIGS. 6 and 7, the wellhead surface structure (10) includesa control and communications system (12) having an interface fortelemetry with downhole instrumentation including a data processor ordata logger (14) and a controller (15) which decodes binary codes fromthe mud pulser and may be linked directly to the user's drillingterminal (16). The decoded data may be yet further transmitted bysatellite (17) beyond the wellhead to a remote operations centre (18)where another user of the drilling software may access the data and thecontrol by means of a telecommunication link (19).

FIG. 8 shows a logic diagram, with a control algorithm that may beconfigured in any number of ways so as to optimize performance.

An exemplary configuration involves a circuit to first cross checkmeasured underreamed wellbore data using the caliper with the recordedblock position data. If the block has been extended by means of thecontrol system yet the data from the caliper for measuring theunderreamed wellbore diameter shows that the actual wellbore diameter isbelow the planned diameter, the processor (68) activates the transponder(72). The transponder communicates with the control area (15) by meansof the mud pulser (56) and corresponding decoder (16) to alert the usereither on the rig (16) or at a remote centre (18) in which casecommunication is made through remote data transmission (17 and 19). Theuser is alerted to check drilling operational parameters and verify theactual underreamed wellbore diameter with that of the desired diameter.

As shown in FIGS. 9 and 10, the illustrated examples are of twoembodiments of the tool sharing common features which is an underreamerthat uses a microprocessor (68) and electronic means to determine andcontrol block position. According to these embodiments of the invention,caliper measurements are not only calibrated by means of fluidproperties sensors but each block is provided with lines or magneticstrips that allow a sensor to detect the actual position of the blocks.The magnetic signal is at its strongest when the block is fully extendedand the magnetic line and sensor are aligned. In this way, it can beseen whether the block has actually been extended and determine itsextension length and position. This data is sent to the processor whereit is stored, compared and correlated with the caliper data. Sensors onthe block or housing (88 a, 86 a) determine the actual position ofblocks (84) and send corresponding signals back to the processor (68).Suitable sensor means include detectors for a magnetic strip,respectively on the cutter block (88 a or 96 a) and housing (86 a or 98a). It is to be noted that the following description of the cutter meansis equally applicable to the structure and function of the stabilizerand expansion means in the uphole section (61) of the tool, with dueallowance for the absence of cutter elements (92).

A set of cutters comprises at least one cutter block (62) carrying aplurality of cutter elements (92) directed outwardly of the tool body(52). The cutter block is received within the tool body in a cutterblock chamber (94) having an open mouth, and the cutter is extendablefrom the chamber through the chamber mouth with the cutter elementsprojecting from the tool body, and retractable back into the chamber. Aseal (104) is provided around the cutter block at the mouth of thereceiving chamber (94).

As noted above, in one embodiment the tool is provided with means forextending and retracting the cutter block from and into the cutter blockchamber, such means may comprise a power mechanism (84) in the tool bodyin engagement with driven teeth (86) on the cutter block. Motor means(80) are provided for extending and retracting the cutter block, andmicroprocessor control means for the motor means are both mounted withinthe tool body. The microprocessor control means is suitably adapted toreceive bore dimension information from the caliper means (66) and tocontrol the cutter block extension in response thereto. A mechanicallock is provided by means of a locking collet finger (96), which can belocated into one of a plurality of retaining lip grooves (98) bytravelling lock (100), which is located by sealing collar (102). Thetool may be activated by means of electronic signal sent by mud-pulseand decoded or by other means using fiber-optics or wirelesstransmission.

Hydraulic locking means may be provided to resist retraction of theextended cutter block (62) into the cutter block chamber (94) when theextension of the cutter block is opposed by external pressure. This maycomprise a port (not shown) open to a source of drilling fluid (passage90) onto the travelling lock (100) immediately behind the cutter block.

The tool normally comprises a plurality of such cutter blocks (62),arranged symmetrically around the tool. Two cutter blocks are onopposite sides of the tool, three blocks are separated by 120 degrees,four by 90 degrees, and six by 60 degrees. In operation, theunderreaming tool (50) is typically rotated on the drill string as wellas being moved axially along the wellbore.

In accordance with an embodiment of the invention, shown in FIG. 9, thecutter block is provided with an internal flowbore (110) leadingdrilling fluid from a through passage (90) to an external nozzle (112)among the cutter elements (92). The source of drilling fluid may be therig pumps via the drill-string (30) to the passage (90) for the flow ofdrilling fluid from the drill string to the drill bit. In anotherembodiment, as shown in FIG. 10, the tool body may be provided with aninternal flowbore (114) leading drilling fluid from passage (90) to anexternal nozzle (116) adjacent the set of cutters. In each embodiment,the nozzle provides an optimized fluid flow that can help to keep thecutters clean and prevent the build-up of clogging debris from theunderreaming operation, remove such material altogether from theunderreaming zone, and provide a cooling and lubricating function forthe cutters.

FIG. 11 shows a further embodiment of the tool wherein a set of cuttersis shown at the downhole end and a further set of cutters are shown atthe uphole end, both sets of cutters suitably housed in modules. Such anembodiment comprises more than one set of expandable cutter blocks (62and 62) integrated within independent modules that are screwed to eachother, with the objective that one module comprises a set of cutterblocks that adapt their expansion to the actual underreamed boreholediameter and that another module has a set of cutter blocks extendedbased on wellbore diameter data received from the caliper in order toreduce drilling downtime.

Those skilled in the art will appreciate that the examples of theinvention given by the specific illustrated and described embodimentsshow a novel underreaming tool and apparatus integrated with a caliperand accompanied by a method for underreaming verification and measuringunderreamed wellbore diameter measurements using calibrated downholefluid property measurements for accurate wellbore diameter measurements.A further embodiment includes a sensor for measuring the position ofextendable blocks. While a further embodiment incorporates a vibrationmeasurement sensor. Consequently, numerous variations are possible toachieve the purpose of the invention which is to improve drillingefficiency and provide certainty whenever a desired underreamed wellborediameter is required. These embodiments are not intended to be limitingwith respect to the scope of the invention. Substitutions, alterationsand modifications not limited to the variations suggested herein may bemade to the disclosed embodiments while remaining within the purpose andscope of the invention.

1. A bottom hole assembly for use in a wellbore comprising a fixeddiameter bit wherein a plurality of cutters extend from a centrallocation to the outer ends of the bit to form a first diameter; and anexpandable reamer wherein a further plurality of cutters providecontinuation from the first diameter and expand to a secondpre-determined diameter by engaging the wellbore in at least 7 differentcircumferential points.
 2. The bottom hole assembly of claim 1 furthercomprising a directional control system.
 3. The bottom hole assembly ofclaim 2 wherein the directional control system is a rotary steerable. 4.The bottom hole assembly of claim 1 wherein cutter placement isoptimised to reduce vibration around the bottom hole assembly.
 5. Thebottom hole assembly of claim 1 further comprising position sensingmeans.
 6. The bottom hole assembly of claim 1 further comprisingborehole diameter sensing means.
 7. The expandable reamer of claim 1wherein the expandable cutters are hard faced.
 8. A method of engagingat least 7 cutters with a wellbore in at least 7 different radiallocations by placing cutters on one or more cutting blocks in arcuateand longitudinal locations.
 9. The method of claim 8 further comprisinga flowpath directly to a reamer cutter face wherein the at least oneflowpath is located on the face or middle of a cutter block and radiatesflow directly across at least one cutter element.
 10. The method ofclaim 8 further comprising a flowpath directly to a reamer cutter facewherein the at least one flowpath is located on the side of a cutterblock and radiates flow directly across at least one cutter element. 11.The method of claim 9 wherein the flow path opens flow between two rowsof cutters.
 12. The method of claim 8 comprising a rotary steerable. 13.The method of claim 8 comprising a position sensing means.
 14. Themethod of claim 8 comprising a wellbore calliper.
 15. An array of cutterelements for drilling an earthen wellbore, wherein cutter elements areset in a helical or diagonal pattern and wherein said pattern isrepeated in at least two substantially parallel rows.
 16. The array ofcutter elements as claimed in claim 15 wherein said cutter elements areset in an expandable cutter block, and preferably set in a plurality ofexpandable cutter blocks distributed uniformly around the body of areamer wherein cutter elements form a helix oriented in the direction ofreaming.
 17. An array of cutter elements as claimed in claim 16 locatedsubstantially in rows extending diagonally across the face of the cutterblock and helically in respect of the wellbore.
 18. An array of cuttersas claimed in claim 17 wherein the helix is oriented in the direction ofupward reaming.
 19. An array of cutters as claimed in claim 16 whereinthe helix forms a continuation of outer ends of drill bit teeth.
 20. Anarray of cutters as claimed in claim 16 wherein the helix engages thewellbore in at least 7 different circumferential points.